U.S. patent application number 16/791034 was filed with the patent office on 2021-08-19 for split power-control electronics with fiber-optic multiplexing.
The applicant listed for this patent is Hamilton Sundstrand Corporation. Invention is credited to Christopher J. Courtney, Michael C. Harke, Mustansir Kheraluwala, Gary L. Miles.
Application Number | 20210258073 16/791034 |
Document ID | / |
Family ID | 1000004690888 |
Filed Date | 2021-08-19 |
United States Patent
Application |
20210258073 |
Kind Code |
A1 |
Miles; Gary L. ; et
al. |
August 19, 2021 |
SPLIT POWER-CONTROL ELECTRONICS WITH FIBER-OPTIC MULTIPLEXING
Abstract
Provided are embodiments of a system for split power-control
electronics with fiber-optic multiplexing. The system includes one
or more power electronics modules configured to provide power to a
load, and a control card configured to control the one or more
power electronics modules. The system also includes a control
module configured to receive and process the control card, and one
or more connections, the one or more connections configured to
connect a control module to the one or more power electronics
modules. Also provided are embodiments of a method for operating
power electronics modules in a redundant mode.
Inventors: |
Miles; Gary L.; (Stillman
Valley, IL) ; Courtney; Christopher J.; (Janesville,
WI) ; Harke; Michael C.; (DeForest, WI) ;
Kheraluwala; Mustansir; (Lake Zurich, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hamilton Sundstrand Corporation |
Charlotte |
NC |
US |
|
|
Family ID: |
1000004690888 |
Appl. No.: |
16/791034 |
Filed: |
February 14, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H04B 10/25 20130101;
B64D 2221/00 20130101; H02J 4/00 20130101; B64D 41/00 20130101 |
International
Class: |
H04B 10/25 20060101
H04B010/25; H02J 4/00 20060101 H02J004/00; B64D 41/00 20060101
B64D041/00 |
Claims
1. A system for split power-control electronics with fiber-optic
multiplexing, the system comprising: one or more power electronics
modules configured to provide power to a load, wherein the load is
a motor; a control card configured to control the one or more power
electronics modules; a control module configured to receive and
process the control card; and one or more connections, the one or
more connections configured to connect a control module to the one
or more power electronics modules.
2. (canceled)
3. The system of claim 1, wherein the one or more connections are
fiber-optic cables.
4. The system of claim 1, wherein the control card is operably
coupled to two or more power electronics modules.
5. The system of claim 1, wherein the control module is in a
separate location from the one or more power electronic
modules.
6. (canceled)
7. The system of claim 1, wherein the control module is in a
separate housing than the one or more power electronics
modules.
8. (canceled)
9. The system of claim 1, wherein the control module is configured
to receive a second control card, wherein the second control card
is configured to operate the one or more power electronics
modules.
10. A method for operating power electronics modules in a redundant
mode, the method comprising: processing, by a control module, a
primary control card to generate control signals; providing the
control signals to one or more power electronics modules over one
or more connections; controlling one or more power electronics
modules based at least in part on the control signals; and
operating a load coupled to the one or more power electronics
modules based on the control signals, wherein the load is a
motor.
11. The method of claim 10, wherein the one or more connections are
fiber-optic cables.
12. The method of claim 10, further comprising operably coupling
the control card to two or more power electronics modules.
13. The method of claim 10, further comprising processing the
control card, by the control module, in a separate location from
the one or more power electronic modules.
14. (canceled)
15. The method of claim 10, wherein the control module is in a
separate housing or chassis than the one or more power electronics
modules.
16. (canceled)
17. The method of claim 10, further comprising receiving, by the
control module, a second control card, wherein the second control
card is configured to operate the one or more power electronics
modules.
18. The method of claim 17, wherein the second control card is
configured in a back-up mode during a failure event of the primary
control card.
19. The method of claim 17, wherein the second control card is
configured in a redundant mode to share control with the primary
control card.
20. (canceled)
Description
BACKGROUND
[0001] The present disclosure relates to electric power systems,
and more specifically, to split power-control electronics with
fiber-optic multiplexing.
[0002] In today's environment, aircraft are incorporating more and
more power electronics (such as motor drives, active rectifiers,
power converters, etc.) for operation. Due to power requirements,
the power electronics tend to be large and heavy taking up the
limited real-estate in the aircraft. In addition, the reliability
of the controls that are used to operate the power electronics must
be maintained as these components are integrated into the aircraft
system.
BRIEF DESCRIPTION
[0003] According to an embodiment, a split power control system
with fiber-optic multiplexing is provided. The system includes one
or more power electronics modules configured to provide power to a
load; a control card configured to control the one or more power
electronics modules; a control module configured to receive and
process the control card; and one or more connections, the one or
more connections configured to connect a control module to the one
or more power electronics modules.
[0004] In addition to one or more of the features described herein,
or as an alternative, further embodiments include a motor load.
[0005] In addition to one or more of the features described herein,
or as an alternative, further embodiments include one or more
connections that are fiber-optic cables.
[0006] In addition to one or more of the features described herein,
or as an alternative, further embodiments include a control card
that is operably coupled to two or more power electronics
modules.
[0007] In addition to one or more of the features described herein,
or as an alternative, further embodiments include a control module
that is in a separate location from the one or more power
electronic modules.
[0008] In addition to one or more of the features described herein,
or as an alternative, further embodiments include a control module
that is located within a temperature-controlled environment.
[0009] In addition to one or more of the features described herein,
or as an alternative, further embodiments include a control module
that is in a separate housing than the one or more power
electronics modules.
[0010] In addition to one or more of the features described herein,
or as an alternative, further embodiments include one or more power
electronics modules that are co-located with the load in an
un-controlled temperature and pressure environment.
[0011] In addition to one or more of the features described herein,
or as an alternative, further embodiments include a control module
that is configured to receive a second control card, wherein the
second control card is configured to operate the one or more power
electronics modules.
[0012] According to an embodiment, a method for operating power
electronics modules in a redundant mode is provided. The method
includes processing, by a control module, a control card to
generate control signals; providing the control signals to one or
more power electronics modules over one or more connections;
controlling one or more power electronics modules based at least in
part on the control signals; and operating a load coupled to the
one or more power electronics modules based on the control
signals.
[0013] In addition to one or more of the features described herein,
or as an alternative, further embodiments include one or more
connections that are fiber-optic cables.
[0014] In addition to one or more of the features described herein,
or as an alternative, further embodiments include operably coupling
the control card to two or more power electronics modules.
[0015] In addition to one or more of the features described herein,
or as an alternative, further embodiments include processing the
control card, by the control module, occurs in a separate location
from the one or more power electronic modules.
[0016] In addition to one or more of the features described herein,
or as an alternative, further embodiments include processing the
control card, by the control module, occurs in a
temperature-controlled environment.
[0017] In addition to one or more of the features described herein,
or as an alternative, further embodiments include a control module
that is located in a separate housing or chassis than the one or
more power electronics modules.
[0018] In addition to one or more of the features described herein,
or as an alternative, further embodiments include one or more power
electronics modules that are co-located with the load.
[0019] In addition to one or more of the features described herein,
or as an alternative, further embodiments include receiving, by the
control module, a second control card, wherein the second control
card is configured to operate the one or more power electronics
modules.
[0020] In addition to one or more of the features described herein,
or as an alternative, further embodiments include using a second
control card that is configured in a back-up mode during a failure
event of a primary control card.
[0021] In addition to one or more of the features described herein,
or as an alternative, further embodiments include using a second
control card that is configured in a redundant mode to share
control with a primary control card.
[0022] In addition to one or more of the features described herein,
or as an alternative, further embodiments include using a second
control card that is configured in a dedicated mode to control the
one or more power electronics modules, respectively.
[0023] The foregoing features and elements may be combined in
various combinations without exclusivity, unless expressly
indicated otherwise. These features and elements as well as the
operation thereof will become more apparent in light of the
following description and the accompanying drawings. It should be
understood, however, that the following description and drawings
are intended to be illustrative and explanatory in nature and
non-limiting.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The following descriptions should not be considered limiting
in any way. With reference to the accompanying drawings, like
elements are numbered alike:
[0025] FIG. 1 depicts a system in accordance with one or more
embodiments of the disclosure;
[0026] FIG. 2 depicts a flowchart of a method in accordance with
one or more embodiments of the disclosure; and
[0027] FIG. 3 depicts an aircraft that may be used in accordance
with one or more embodiments of the disclosure.
DETAILED DESCRIPTION
[0028] In existing architectures, power electronics tend to be
packaged in large units that contain all of the control modules and
high power components. In some cases, they are coupled or packaged
with the load. Since the heat-producing power components are in
proximity to the control modules, the low-power control components
can become thermally stressed.
[0029] In order to reduce the overheating of these devices various
cooling techniques can be used. Techniques can include large
passive heat sinks or active cooling provided by fans or liquid
cooling. These mechanisms also take up space in the limited areas
of the aircraft. The overheating of these components can lead to
failing components resulting in reduced reliability of the
system.
[0030] The techniques described herein provide for re-locating the
low-power, thermally-limited, sensitive electronics from the
high-heat producing power electronic components. That is, the
low-power control elements are split (physically separated) from
the large heat-producing power electronics elements that are used
for driving the load and are placed within temperature-controlled
environments. The low-power control electronics are coupled to the
high-power electronics using fiber-optic cables. The fiber-optic
cables are much lighter than the conventional copper-based cables.
In addition, given the much higher bandwidth capabilities of the
fiber-optic cables, a single cable can be used to transmit (or
multiplex) multiple signals as compared to conventional
copper-based signal cables which can couple only one signal.
[0031] FIG. 1 depicts a system 100 of an architecture for a
split-power control electronics system with multiplexing in
accordance with one or more embodiments. As shown in FIG. 1, the
system 100 includes electrical machines (motor, generator) 102 and
104 that are driven by power from the power electronics 106 and
108, respectively. The power electronics 106, 108 receive power
from a power source. Example power electronics 106, 108 can include
but are not limited to insulated-gate bipolar transistors (IGBT),
gate-drives, other high-power electronic switches, filters, etc. In
one or more embodiments of the disclosure, the power electronics
106, 108 are used to drive the electrical machines 102, 104,
respectively. An example electrical machine can include a 3-phase
motor as shown.
[0032] The system 100 also includes a card control module 110 that
is configured to receive motor control cards 112 and 114. The motor
drive control cards 112 and 114 can be operably connected to and
processed by the control module 110. In one or more embodiments of
the disclosure, a single motor drive control card 112 can operate
both of the power electronics 106 and 108. In other embodiments, a
redundant motor control card can be configured to operate both of
the power electronics 106, 108 in the event there is a failure in
the primary motor drive control card. In some other embodiments,
the first and second motor drive control cards can be configured to
operate half of the power electronics or be dedicatedly configured
to each respective power electronics 106, 108. It should be
understood the motor drive control cards 112, 114 can be configured
in different arrangements and is not limited by those described
herein. The arrangement of the motor drive control cards provides
for back-up modes, redundant modes, and dedicated modes of
operation. In addition, it can reduce the complexity of the system
100.
[0033] The control module 110 provides control signals to control
the power electronics 106 over a first connection 116 and over a
second connection 118. A first channel includes the motor 102, the
power electronics 106, and the first fiber-optic connection 116,
and the second channel includes the motor 104, the power
electronics 108, and the connections 118. Although only two
channels are shown, it should be understood that additional
channels can be implemented and are not limited by the architecture
shown in FIG. 1.
[0034] In some embodiments of the disclosure, the connections 116
and 118 are fiber-optic cables. The optical fiber elements of the
fiber-optic cables are packaged in bundles and carry signals in the
form of light. The fiber-optic cables are capable of transmitting
data at very high speeds. In addition, the fiber-optic cables are
robust enough to limit the interference or cross-talk from unwanted
sources such as neighboring cables.
[0035] In one or more embodiment of the disclosure, the high power
electronics 106, 108 can be co-located with the motors 102, 104 to
minimize the power-feeder weight used for the connection.
Co-locating high power electronics and a motor or generator,
results in reducing or eliminating bulky power quality filters in
the power electronics section to further help reduce the weight and
size. In addition, the high-power electronics 106, 108 and the
motors 102, 104 can share cooling systems to conserve the limited
space of the aircraft.
[0036] FIG. 2 depicts a method 200 for operating a split power
control system in accordance with one or more embodiments of the
disclosure. The method 200 begins at block 202 and proceeds to
block 204 which provides for processing, by a control module, a
control card to generate control signals. Block 206 provides the
control signals to one or more power electronics modules over one
or more connections. In one or more embodiments the control card
and control module are located in a separate location from the
power electronics modules. The control modules are coupled to the
power electronics modules using fiber-optic cables which are
capable of multiplexing a plurality of control signals over the
same cable. In addition, by locating the control cards and control
module away from the higher heat-producing power
components/electronics, failure from thermal stress is greatly
reduced. Block 208 controls one or more power electronics modules
based at least in part on the control signals, and block 210
operates a load (motor) coupled to the one or more power
electronics modules based on the control signals. The method 200
ends at block 212. It should be understood that additional steps
can be used and is not intended to be limited by the steps shown in
FIG. 2.
[0037] FIG. 3 depicts an aircraft 300 that can implement the system
100 in accordance with one or more embodiments. It should be
understood the architecture of the system 100 separating the power
electronics 106, 108 from the control card(s) 112, 114 can be
implemented in any vehicle and is not limited by the aircraft 300
shown in FIG. 3. In one or more embodiments of the disclosure, the
control module 110, the motor drive control cards 112, 114 are
located in an environmentally-regulated electronics bay. The
low-power electronics are easier to cool when they are located
within the aircraft and provide for a better environment for
increased reliability. The motors 102, 104 and power electronics
106, 108 are co-located and leverage the same cooling systems.
[0038] The techniques described herein provide a layout for split
power-control electronics architecture that separates the low-power
control elements from large heat-producing power electronics
elements driving the motors. In addition, a single card can now
control multiple power electronics modules by multiplexing the data
over the fiber-optic cables, unlike the conventional systems that
require dedicated control cards.
[0039] A detailed description of one or more embodiments of the
disclosed apparatus and method are presented herein by way of
exemplification and not limitation with reference to the
Figures.
[0040] The term "about" is intended to include the degree of error
associated with measurement of the particular quantity based upon
the equipment available at the time of filing the application.
[0041] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the present disclosure. As used herein, the singular forms "a",
"an" and "the" are intended to include the plural forms as well,
unless the context clearly indicates otherwise. It will be further
understood that the terms "comprises" and/or "comprising," when
used in this specification, specify the presence of stated
features, integers, steps, operations, elements, and/or components,
but do not preclude the presence or addition of one or more other
features, integers, steps, operations, element components, and/or
groups thereof.
[0042] While the present disclosure has been described with
reference to an exemplary embodiment or embodiments, it will be
understood by those skilled in the art that various changes may be
made, and equivalents may be substituted for elements thereof
without departing from the scope of the present disclosure. In
addition, many modifications may be made to adapt a particular
situation or material to the teachings of the present disclosure
without departing from the essential scope thereof. Therefore, it
is intended that the present disclosure not be limited to the
particular embodiment disclosed as the best mode contemplated for
carrying out this present disclosure, but that the present
disclosure will include all embodiments falling within the scope of
the claims.
[0043] The computer-readable storage medium can be a tangible
device that can retain and store instructions for use by an
instruction execution device. The computer-readable storage medium
may be, for example, but is not limited to, an electronic storage
device, a magnetic storage device, an optical storage device, an
electromagnetic storage device, a semiconductor storage device, or
any suitable combination of the foregoing. A non-exhaustive list of
more specific examples of the computer-readable storage medium
includes the following: a portable computer diskette, a hard disk,
a random access memory (RAM), a read-only memory (ROM), an erasable
programmable read-only memory (EPROM or Flash memory), a static
random access memory (SRAM), a portable compact disc read-only
memory (CD-ROM), a digital versatile disk (DVD), a memory stick, a
floppy disk, a mechanically encoded device such as punch-cards or
raised structures in a groove having instructions recorded thereon,
and any suitable combination of the foregoing. A computer-readable
storage medium, as used herein, is not to be construed as being
transitory signals per se, such as radio waves or other freely
propagating electromagnetic waves, electromagnetic waves
propagating through a waveguide or other transmission media (e.g.,
light pulses passing through a fiber-optic cable), or electrical
signals transmitted through a wire.
[0044] Computer-readable program instructions described herein can
be downloaded to respective computing/processing devices from a
computer-readable storage medium or to an external computer or
external storage device via a network, for example, the Internet, a
local area network, a wide area network and/or a wireless network.
The network may comprise copper transmission cables, optical
transmission fibers, wireless transmission, routers, firewalls,
switches, gateway computers and/or edge servers. A network adapter
card or network interface in each computing/processing device
receives computer-readable program instructions from the network
and forwards the computer-readable program instructions for storage
in a computer-readable storage medium within the respective
computing/processing device.
[0045] Aspects of the present invention are described herein with
reference to flowchart illustrations and/or block diagrams of
methods, apparatus (systems), and computer program products
according to embodiments. It will be understood that each block of
the flowchart illustrations and/or block diagrams, and combinations
of blocks in the flowchart illustrations and/or block diagrams, can
be implemented by computer-readable program instructions.
[0046] The flowchart and block diagrams in the Figures illustrate
the architecture, functionality, and operation of possible
implementations of systems, methods, and computer program products
according to various embodiments. In this regard, each block in the
flowchart or block diagrams may represent a module, segment, or
portion of instructions, which comprises one or more executable
instructions for implementing the specified logical function(s). In
some alternative implementations, the functions noted in the blocks
may occur out of the order noted in the Figures. For example, two
blocks shown in succession may, in fact, be executed substantially
concurrently, or the blocks may sometimes be executed in the
reverse order, depending upon the functionality involved. It will
also be noted that each block of the block diagrams and/or
flowchart illustration, and combinations of blocks in the block
diagrams and/or flowchart illustration, can be implemented by
special purpose hardware-based systems that perform the specified
functions or acts or carry out combinations of special purpose
hardware and computer instructions.
[0047] While the present disclosure has been described in detail in
connection with only a limited number of embodiments, it should be
readily understood that the present disclosure is not limited to
such disclosed embodiments. Rather, the present disclosure can be
modified to incorporate any number of variations, alterations,
substitutions, combinations, sub-combinations, or equivalent
arrangements not heretofore described, but which are commensurate
with the scope of the present disclosure. Additionally, while
various embodiments of the present disclosure have been described,
it is to be understood that aspects of the present disclosure may
include only some of the described embodiments.
[0048] The descriptions of the various embodiments have been
presented for purposes of illustration but are not intended to be
exhaustive or limited to the embodiments disclosed. Many
modifications and variations will be apparent to those of ordinary
skill in the art without departing from the scope and spirit of the
described embodiments. The terminology used herein was chosen to
best explain the principles of the embodiments, the practical
application or technical improvement over technologies found in the
marketplace, or to enable others of ordinary skill in the art to
understand the embodiments disclosed herein.
* * * * *